Condensation and humidity sensors for thermoelectric devices

ABSTRACT

According to certain embodiments disclosed in the present application, a climate controlled seating assembly includes a thermal module. The thermal module comprises at least one inlet channel, at least one outlet channel and a thermoelectric device (e.g., Peltier circuit) positioned upstream of the outlet channel. In one embodiment, the seating assembly includes a sensor positioned within an interior of the thermal module and configured to detect the presence of a liquid, such as water, condensation or other fluids, on or near said sensor. In certain arrangements, the sensor is configured to detect the presence of a liquid by measuring an electrical resistance or capacitance across a portion of the sensor. A climate control system can include a separator gasket located within a housing of a fluid module and at least partially between the cold passage and the hot passage. In some embodiments, the separator gasket comprises one or more wicking materials. The separator gasket can be configured to transport liquids from the cold passage to the hot passage.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/307,988, filed Jun. 18, 2014, which is a continuation of U.S. patentapplication Ser. No. 13/963,216, filed Aug. 9, 2013, which iscontinuation of U.S. patent application Ser. No. 13/599,896, filed Aug.30, 2012 and issued as U.S. Pat. No. 8,505,320, which is a continuationof U.S. patent application Ser. No. 12/364,285, filed Feb. 2, 2009 andissued as U.S. Pat. No. 8,256,236 on Sep. 4, 2012, which claims thepriority benefit under 35 U.S.C. §119(e) of U.S. Provisional PatentApplication No. 61/025,694, filed Feb. 1, 2008, and U.S. ProvisionalPatent Application No. 61/025,719, filed Feb. 1, 2008, the entireties ofU.S. application Ser. No. 12/364,285, filed Feb. 2, 2009, U.S.Provisional Patent Application No. 61/025,694, filed Feb. 1, 2008, andU.S. Provisional Patent Application No. 61/025,719, filed Feb. 1, 2008are hereby incorporated by reference herein.

BACKGROUND

1. Field of the Inventions

This application relates generally to climate control, and morespecifically, to climate control of seating assemblies utilizing athermoelectric circuit.

2. Description of the Related Art

Temperature modified air for environmental control of living or workingspace is typically provided to relatively extensive areas, such asentire buildings, selected offices, or suites of rooms within abuilding. In the case of vehicles, such as automobiles, the entirevehicle is typically cooled or heated as a unit. There are manysituations, however, in which more selective or restrictive airtemperature modification is desirable. For example, it is oftendesirable to provide individualized climate control for an occupant seatso that substantially instantaneous heating or cooling can be achieved.For example, an automotive vehicle exposed to the summer weather,especially where the vehicle has been parked in an unshaded area for along period of time, can cause the vehicle seat to be very hot anduncomfortable for the occupant for some time after entering and usingthe vehicle, even with normal air conditioning. Furthermore, even withnormal air-conditioning, on a hot day, the seat occupant's back andother pressure points may remain sweaty while seated. In the wintertime, it may be desirable to quickly warm the seat of the occupant inorder to enhance an occupant's comfort. This is particularly true wherea typical vehicle heater is unlikely to quickly warm the vehicle'sinterior. For these and other reasons, there have long been varioustypes of individualized climate control systems for vehicle seats. Morerecently, individualized climate control systems have been extended tobeds, chairs, wheelchairs, other medical beds or chairs and the like.

Such climate control systems typically include a distribution systemcomprising a combination of channels and passages formed in one or morecushions of a seat. Climate conditioned air can be supplied to thesechannels and passages by using a climate controlled device. Climateconditioned air flows through the channels and passages to cool or heatthe space adjacent the surface of the vehicle seat.

There are, however, problems that have been experienced with existingclimate control systems. For example, some control systems utilizethermoelectric devices (TEDs) that can have a variety of configurationson the hot and main sides of the device. For configurations in whichthere is a heat exchanger on the main side with air flowing past it,condensation may form from water in the air. Whether or not condensationwill occur and how much condensation will occur depends on the ambientair conditions (i.e. temperature and relative humidity) and the amountof temperature reduction from the inlet of the main side heat exchangerto the outlet. This condensation often can have undesirableconsequences, from corrosion on metal parts to the creation of mold.Condensation may also partially or totally block airflow at the finpassages on the main side of the TED, resulting in reduction or loss offunction.

SUMMARY

According to certain embodiments disclosed in the present application, aclimate controlled seating assembly includes a thermal module. Thethermal module comprises at least one inlet channel, at least one outletchannel and a thermoelectric device (e.g., Peltier circuit) positionedupstream of the outlet channel. According to some arrangements, thethermoelectric device is configured to selectively heat or cool a fluidpassing through an interior of the thermal module. The climatecontrolled seating assembly additionally includes a fluid transferdevice, such as a fan or blower, that is configured to transfer a fluidfrom the inlet channel to the outlet channel of the thermal module, pastthe thermoelectric device. In one embodiment, the seating assemblyfurther includes a sensor positioned within an interior of the thermalmodule and configured to detect the presence of a liquid, such as water,condensation or other fluids, on or near said sensor. In certainarrangements, the sensor is configured to detect the presence of aliquid by measuring an electrical resistance or capacitance across aportion of the sensor. Alternatively, the sensor can detect the presenceof a liquid using any other method.

According to some embodiments, the sensor comprises at least first andsecond conductive members (e.g., electrical traces). In one embodiment,the sensor is configured to measure the electrical resistance orcapacitance across the traces or other conductive members. In anotherconfiguration, the sensor is positioned on the thermoelectric device oralong a cooling side of the thermoelectric device. In some embodiments,the sensor is positioned along the outlet channel that is adapted toreceive a fluid (e.g., air) cooled by the thermoelectric device.

In other arrangements, the first conductive member and/or the secondconductive member are etched onto a substrate of the thermoelectricdevice. In another configuration, the substrate comprises polyimide,epoxy, ceramic or any other suitable material. In other embodiments, avoltage supplied to the thermoelectric device is configured to bereduced if the presence of a liquid is detected by the sensor. Accordingto other arrangements, the seating assembly comprises an automobile orother type of vehicle seat, a bed, a wheelchair, a sofa, an officechair, a medical bed and/or the like.

In accordance with certain embodiments of the present application, amethod of controlling a thermoelectric device configured for use in aclimate controlled seat assembly includes providing a fluid moduleadapted to provide heated or cooled air to the climate controlled seatassembly. In some arrangements, the fluid module includes athermoelectric device configured to selectively heat or cool air passingthrough an interior of the fluid module and a fluid transfer device(e.g., fan, blower, etc.) configured to transfer air through theinterior of the fluid module, past the thermoelectric device. The methodadditionally includes positioning a sensor within the fluid module,wherein the sensor is configured to detect condensates and/or otherliquids with which it comes into contact. Further, the method includesdirecting a first voltage to the thermoelectric device to selectivelyheat or cool air being transferred through fluid module. In someembodiments, a second voltage, which is less than the first voltage, isdirected to the thermoelectric device when the sensor detectscondensates and/or other liquids.

In certain arrangements, the sensor is configured to detect condensatesand/or other liquids by measuring an electrical resistance orcapacitance across a portion of the sensor. In some embodiments, thesensor positively detects condensates and/or other liquids when theelectrical resistance or capacitance across it changes by at least 2%,5%, 10%, 20% or more than 20% over a 1-minute, 2-minute, 5-minute,10-minute or 15-minute time period (or time periods less than 1 minute,greater than 15 minutes and/or any other time period. In someembodiments, the second voltage is zero so that no current is suppliedto the thermoelectric device. Thus, the thermoelectric device can bedeactivated when the sensor detects condensate and/or other liquids. Inanother arrangement, the sensor is positioned on the thermoelectricdevice or along a cooling side of the thermoelectric device. In otherembodiments, the sensor is positioned along an outlet of the fluidmodule positioned generally downstream of the thermoelectric device. Theoutlet can be configured to receive air which has been cooled by thethermoelectric device.

According to another embodiment, a fluid conditioning device for usewith a climate controlled seating assembly includes a fluid modulecomprising a housing, a fluid transfer device configured to convey afluid through an interior of the housing, and a thermoelectric deviceconfigured to selectively heat or cool fluids passing within theinterior of the housing. The thermoelectric device can comprise a hotside and a cold side, with the hot side being in fluid communicationwith a hot passage and the cold side being in fluid communication with acold passage. In some arrangements, the hot passage is configured toreceive air heated by the thermoelectric device and the cold passage isconfigured to receive air cooled by the thermoelectric device. The hotand cold passages are located downstream of the thermoelectric deviceand within the housing of the fluid module. The fluid condition devicefurther includes a separator gasket located within the housing and atleast partially between the cold passage and the hot passage. In someembodiments, the separator gasket comprises one or more wickingmaterials. The separator gasket can be configured to transport liquidsfrom the cold passage to the hot passage.

In some embodiments, the separator gasket comprises a porous structure.In other arrangements, the wicking material comprises polypropylene,nylon and/or any other material or configuration. In other arrangements,liquids transported to the hot passage are configured to be evaporated.In another embodiment, the fluid conditioning device additionallyincludes at least one finger of wicking material that extends at leastpartially through the housing to the thermoelectric device. The fingerof wicking material can be configured to transport liquids from thethermoelectric device to the separator gasket.

According to certain embodiments of the present application, a method ofautomatically regulating a climate controlled seating assembly using anautomated control scheme includes providing a fluid module that is influid communication with at least one fluid distribution channel of theseating assembly. In some embodiments, the fluid module comprises athermoelectric device configured to selectively heat or cool fluidspassing through the fluid module and a fluid transfer device configuredto transfer fluids through the fluid module. The fluid transfer deviceincludes an inlet and an outlet. The method of automatically regulatinga seating assembly additionally includes detecting a temperature offluid exiting the outlet of the fluid transfer device, detecting arelative humidity of fluid exiting the outlet of the fluid transferdevice and providing the temperature and the relative humidity as inputsinto a control scheme protocol. Further, the method comprises modifyingan operational parameter of the thermoelectric device and/or the fluidtransfer device based on instructions provided by the control schemeprotocol.

In some embodiments, the seating assembly comprises an automobile seat,another vehicle seat, a bed, a wheelchair, an office chair, a sofa, amedical bed and/or the like. In some embodiments, the method alsoincludes detecting a temperature of ambient air. The control schemeprotocol can be configured to receive the temperature of ambient air asan input. In other arrangements, the method also includes detecting apresence of an occupant positioned on the seating assembly using anoccupant detection sensor. In one embodiment, modifying an operationalparameter comprises adjusting a voltage or current supplied to thethermoelectric device, adjusting the speed of the fluid transfer deviceand/or the like.

In some configurations a thermoelectric device can comprise a Peltiercircuit and a sensor which determines the presence of a fluid at thesensor by measuring a change in either resistance or capacitance. Thevoltage to the thermoelectric device can be decreased or eliminatedcompletely when the sensor measures such a change in resistance orcapacitance. The fluid may be water or condensation formed within aclimate controlled system.

In some embodiments the thermoelectric device comprises a ledge whichprojects past the Peltier circuit wherein part of or the entire sensoris located on the ledge. The ledge may comprise a substrate. Thesubstrate may be formed of copper.

In some embodiments the sensor is on a main side of the thermoelectricdevice.

A thermoelectric device may comprise a Peltier circuit, at least one finand a sensor which determines the presence of water at the sensor bymeasuring a change in either resistance or capacitance. The sensor maybe downstream of the at least one fin.

A sensor to detect the presence of a fluid at the sensor may compriseone or more conductive traces. Where the sensor comprises two or moreconductive traces, the traces may be maintained at substantially equalspacing apart from each other. The sensor may measure a change inresistance across the two traces. The change in resistance may be anabsolute change or a rapid change over a short period of time. Where thesensor comprises one trace the sensor may further comprise a conductivesurface. The conductive surface may comprise a heat transfer member suchat least one fin. The sensor may measure a change in resistance acrossthe trace and the heat transfer member.

In some embodiments the trace is (are) etched onto a substrate. Thesubstrate may comprise polyimide.

A sensor to detect the presence of a fluid at the sensor may alsomeasure capacitance instead of resistance. A sensor may comprise a firstand second conductive plate and a material that absorbs water inbetweenthe first and second conductive plates. In some embodiments the materialinbetween comprises polyimide and the first and second conductive platesmay comprise copper.

In some embodiments the first conductive plate may comprise electricaljoining tabs that are part of the TED. The second conductive plate maycomprise a thermal conductive element, also part of the TED. Thematerial inbetween may comprise a substrate which is also part of theTED.

In some embodiments of a sensor that uses capacitance to detect thepresence of a fluid, the second conductive plate comprises at least onehole etched into the surface of the plate to increase the surface areaof the material inbetween that is exposed to absorption of the fluid.The hole(s) may be located generally across the substrate or they may belocated at a spot of high likelihood of condensation formation.

A climate conditioned vehicle seat may comprise a fluid distributionsystem, and a fluid module, comprising a fluid transfer device, athermoelectric device and a sensor which determines the presence ofwater at the sensor by measuring a change in either resistance orcapacitance. The climate conditioned vehicle seat may further comprise avoltage reduction to the thermoelectric device when the sensor measuresa change in resistance or capacitance.

A climate conditioned bed may comprise a fluid distribution system, anda fluid module, comprising a fluid transfer device, a thermoelectricdevice and a sensor which determines the presence of water at the sensorby measuring a change in either resistance or capacitance. The climateconditioned bed may further comprise a voltage reduction to thethermoelectric device when the sensor measures a change in resistance orcapacitance.

One configuration of a TED assembly has fins on both sides of the TEDand air blowing past both sides. Downstream of the fins, it is oftendesired to have the hot and cold airstreams separated from each other sothat the conditioned air can be used for a functional purpose. Onemethod of doing this is to place a piece of foam in between the hot andcold fins that will physically separate the airstreams and also act as athermal barrier between them (e.g. to prevent the hot air from heatingup the cooled air).

One embodiment of the invention replaces this (typically foam) separatorgasket with a wicking separator gasket. If condensation does occur onthe cold side airflow, the water formed will wick across the separatorgasket to the other side (with hot air flowing past it) and beevaporated and carried away by the hot air. In this manner, thecondensation formed is removed from the cold side of the TED.

For conditions in which water condenses on the cold side of a TEDassembly, the wicking separator gasket will remove the condensed liquid.

This allows TED assemblies to be designed with higher thermalperformance than would otherwise be achievable. In other words, the TEDcan be designed to provide a higher change in temperature on the coldside air stream. Alternately, the TED can be operated in high humidityambient environments.

In another embodiment, finger wicks can extend between the cold sidefins of a TED and lead to a hot side of the airstream. The fingers wickcan draw moisture away from the fins and to the hot side of theairstream; this moisture can then be evaporated into the hot air.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the presentinventions are described herein in connection with certain preferredembodiments, in reference to the accompanying drawings. The illustratedembodiments, however, are merely examples and are not intended to limitthe inventions. The drawings include the following figures.

FIG. 1 illustrates a side schematic view of a climate controlled vehicleseat according to one embodiment;

FIG. 2 illustrates a perspective schematic view of a climate controlledbed according to one embodiment;

FIG. 3 illustrates a partial cross-sectional view of a fluid moduleaccording to one embodiment;

FIG. 4A illustrates a partial cross-sectional view of a fluid modulecomprising a wicking separator gasket according to one embodiment;

FIG. 4B illustrates a partial cross-sectional view of the fluid moduleof FIG. 4A when condensation is present;

FIG. 5 illustrates a partial cross-sectional view of a fluid modulecomprising a finger wick and a wicking separator gasket according to oneembodiment;

FIG. 6A illustrates a top schematic view of one embodiment of aresistance based condensation sensor;

FIG. 6B illustrates a top schematic view of a sensing zone of thecondensation sensor of FIG. 6A;

FIG. 6C illustrates a top schematic view of another embodiment of aresistance based condensation sensor;

FIG. 6D illustrates a top schematic view of still another embodiment ofa resistance based condensation sensor;

FIG. 6E illustrates a top schematic view of yet another embodiment of aresistance based condensation sensor;

FIG. 7 illustrates a perspective view of another embodiment of aresistance-based condensation sensor;

FIG. 8 illustrates a chart showing change in resistance measured at aresistance-based condensate sensor over time, according to oneembodiment;

FIG. 9A illustrates an exploded perspective view of a thermoelectricdevice according to one embodiment;

FIG. 9B illustrates a perspective view of an assembled version of thethermoelectric device of FIG. 9A;

FIG. 10A illustrates a partial cross-sectional view of a fluid modulecomprising a condensation sensor according to one embodiment;

FIG. 10B illustrates a perspective view of an assembled version of athermoelectric device comprising a resistance based condensation sensoraccording to one embodiment;

FIG. 10C illustrates a perspective view of an assembled version of athermoelectric device comprising a resistance based condensation sensoraccording to another embodiment;

FIG. 11A illustrates a schematic perspective view demonstrating thegeneral principles of a capacitance based condensation sensor accordingto one embodiment;

FIG. 11B illustrates an exploded perspective view of a condensationsensor that uses capacitance to detect the presence of a fluid accordingto one embodiment;

FIG. 12 illustrates an embodiment of an electrical circuit comprising acondensation sensor;

FIG. 13 illustrates one embodiment of a comfort zone in relation totemperature and relative humidity;

FIG. 14A illustrates one embodiment of a climate controlled seatingassembly comprising a plurality of sensors according to one embodiment;and

FIG. 14B illustrates one embodiment of a climate controlled bedcomprising a plurality of sensors according to one embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A variety of examples described below illustrate various configurationsthat may be employed to achieve desired improvements. The particularembodiments and examples are only illustrative and not intended in anyway to restrict the general inventions presented and the various aspectsand features of these inventions. In addition, it should be understoodthat the terms cooling side, heating side, main side, waste side, coolerside and hotter side and the like do not indicate any particulartemperature, but are relative terms. For example, the “hot,” “heating”or “hotter” side of a thermoelectric device or array may be at ambienttemperature, with the “cold,” “cooling” or “cooler” side at a coolertemperature than ambient. Conversely, the “cold,” “cooling” or “cooler”side may be at ambient with the “hot,” “heating” or “hotter” side at ahigher temperature than ambient. Thus, the terms are relative to eachother to indicate that one side of the thermoelectric device is at ahigher or lower temperature than the counter or opposing side. Moreover,as is known in the art, when the electrical current in a thermoelectricdevice is reversed, heat can be transferred to the “cold” side of thedevice, while heat is drawn from the “hot” side of the device. Inaddition, fluid flow is referenced in the discussion below as havingdirections. When such references are made, they generally refer to thedirection as depicted in the two dimensional figures. The terminologyindicating “away” from or “along” or any other fluid flow directiondescribed in the application is meant to be an illustrativegeneralization of the direction of flow as considered from theperspective of two dimensional figures.

FIG. 1 is a schematic diagram of a climate controlled vehicle seat 10.The depicted climate controlled vehicle seat 10 includes a seat back 2,a seat bottom 4, a fluid distribution system 12 and a fluid module 14.The terms “fluid module” and “thermal module” are used interchangeablyherein. The fluid module 14 can include a fluid transfer device 16 and athermoelectric device (TED) 18. The fluid transfer device 16 comprises,for example, a blower or a fan. FIG. 1 illustrates one embodiment of aclimate controlled vehicle seat 10 wherein air or other fluids, whichare thermally conditioned by the fluid module 14, can be selectivelytransferred from the fluid module 14, through the fluid distributionsystem 12 and toward a occupant positioned on the vehicle seat 10. Whilecomponents of the fluid module 14 (e.g., the TED 18, fluid transferdevice 16, the distribution system 12) are illustrated outside the seat10, one or more of these components can be positioned entirely orpartially within the seat 10, as desired or required.

As illustrated in FIG. 1, the seat assembly 10 can be similar to astandard automotive seat. However, it should be appreciated that certainfeatures and aspects of the seat assembly 10 described herein may alsobe used in a variety of other applications and environments. Forexample, certain features and aspects of the seat assembly 10 may beadapted for use in other vehicles, such as, for example, airplanes,trains, boats and/or the like. In other arrangements, as discussed ingreater detail herein, the seat assembly can include a bed (FIG. 2), amedical bed, a chair, a couch, a wheelchair, another medical bed orchair and/or any other device configured to support one or moreoccupants.

For instance, FIG. 2 illustrates a schematic diagram of a climatecontrolled bed 10B. The depicted arrangement of a climate controlled bed10B includes a cushion 3, a fluid distribution system 12 and a fluidmodule 14. The fluid module 14 can include a fluid transfer device 16(e.g., a fan, blower, etc.), a TED 18 and any other devices orcomponents (e.g., sensors), as desired or required. FIG. 2 illustratesonly one configuration of a climate controlled bed 10B wherein the fluidmodule 14 is conditioned and transferred from the fluid module 14,through the fluid distribution system 12 to the ultimate user sitting orlying on the bed 10B.

With continued reference to FIG. 2, the bed assembly 10B can be similarto a standard bed. However, one or more features and aspects of the bedassembly 10B described herein may also be used in a variety of otherapplications and environments. For example, certain features and aspectsof the bed assembly 10B may be adapted for use in other stationaryenvironments, such as, for example, a chair, a sofa, a theater seat, andan office seat that is used in a place of business and/or residence.

With reference to FIG. 3, a fluid transfer device 116 of a fluid module114 can be configured to provide a fluid, usually air, to an inlet 130of a TED 118. As discussed in greater detail herein, the TED can includea hot side 124 and a cold side 122. Fluids being directed through thefluid module 114 are generally divided between the hot side 124 and thecold side 122. From the cold side 122 of the TED 118, fluids leave via acold side outlet 132 that leads to the fluid distribution system 112 ofa seat assembly. On the other hand, from the hot side 124 of the TED 18,fluids leave via a hot side outlet 134 that may be in fluidcommunication with a waste duct. Such a waste duct can convey the fluidsto an area where they will not affect the user of the conditioningsystem or the operation of the conditioning system itself.

According to certain arrangements, fluids are selectivelythermally-conditioned as they pass through or near the TED 118. Thus,fluids leaving the TED 118 through the cold side outlet 132 arerelatively cold, and fluids leaving the TED 118 through the hot sideoutlet 134 are relatively warm. Further, a separator gasket 151 can begenerally positioned between the cold side outlet 132 and the hot sideoutlet 134. The separator gasket 151 can comprise a foam (e.g., closedcell, open cell, etc.) and/or any other material. In certainarrangements, the separator gasket 151 is used to both separate the hotand cold fluid flows and to thermally isolate them.

Condensate Wicking

With continued reference to FIG. 3, problems may arise when the changein temperature on the cold side 122 of a TED rises above the dew point.For example, this can cause condensation to form. The condensation mayform, for example, within the TED 18, in the cold side outlet 132 and/orat any other location within or near the TED 118 or the fluid module114.

Condensation formed within a fluid module can cause a number ofpotential problems. For example, a plurality of fins can be providedalong the cold side 122 and/or the hot side 124 of a TED 118 to helptransfer heat to or from air or other fluids passing through a fluidmodule 114. Based on the temperature variations within a TED,condensation can form on the fins, generally decreasing the effectivesurface area of the fins. Consequently, the flow of air or other fluidsthrough the cold side 122 of the TED 118 can be partially or completelyimpeded. Under such conditions, the temperature on the cold side 122 maydecrease to the point where ice forms within the TED 118 and/or alongthe cold side outlet 132. Ice formation may further limit fluid flowthrough the fluid module 114, and thus, may undesirably prevent thethermal conditioning system from functioning properly.

Additionally, as condensation forms it may pool or otherwise collect onor within the TED 118 and/or other portions of the thermal module 114.In some embodiments, condensed water or other fluid can move to otherdownstream locations of the seat assembly where it can cause furtherproblems. For example, such condensate can be transferred to the fluiddistribution system and/or the cushion of a seat assembly. As a result,mold, rust, oxidation, moisture damage, stains and/or other problems mayresult. The condensate may also decrease the comfort level of the user.For example, under some conditions, moist or wet air may be blown on auser's legs, back and/or other portions of an occupant's body. Further,the condensate may create odor problems within the automobile, room orother location where the seat assembly is located.

FIG. 4A illustrates one embodiment adapted to address the condensateformation and pooling problems discussed herein. In the depictedarrangement, the fluid module 114A comprises, inter alia, a fluidtransfer device 116A and a TED 118A. As shown, the TED 118A can belocated downstream of a fan or other fluid transfer device 116A.However, in any of the embodiments disclosed herein, a TED can bealternatively located upstream of a fluid transfer device, as desired orrequired. The fluid transfer device 116A can be adapted to transfer airor other fluids to an inlet 130A of the TED 118A. In some arrangements,the TED 118A includes a hot side 124A and a cold side 122A. Thus, fluidflow can be selectively advanced through the inlet 130A and into the TED118A, where the fluid can be divided between the hot side 124A and thecold side 122A. From the cold side 122A of the TED 118A, the fluidleaves via a cold side outlet 132A that leads to the fluid distributionsystem 112A. Likewise, from the hot side 124A of the TED 118A, the fluidleaves via a hot side outlet 134A toward a waste duct.

According to some embodiments, as illustrated in FIG. 4A, a wickingseparator gasket 155A is provided generally between the cold side outlet132A and the hot side outlet 134A. The wicking separator gasket 155A canbe configured so that it wicks water and/or other fluids that condenseor otherwise form within a fluid module 114A away from the cold side122A and to the hot side 124A. FIG. 4B demonstrates one embodiment ofcondensed water 170A and/or other fluids generally passing from the coldside to the hot side through the wicking separator gasket 155A. In someembodiments, water or other liquid entering the hot side can beadvantageously evaporated or otherwise removed from the fluid module114A.

In other embodiments, as shown in FIG. 5, a wicking separator gasket 159comprises, is coupled to, forms a part of or is otherwise in fluidcommunication with at least one finger or extension wick 157. Forexample, such finger wicks 157 can be configured to extend next to orbetween one or more fins on the cold side 122 of the TED 118. The fingerwick 157 can be configured to provide quicker, more efficient and moreeffective absorption of condensation. In other arrangements, fingerwicks 157 can be used with the separator gasket, but without the use ofa wicking separator gasket. The finger wick may be configured such thatit generally wicks or otherwise transfers water or other condensationaway from the cold side to the hot side where it can be advantageouslyevaporated or otherwise removed from the fluid module 114. Accordingly,the use of finger wicks can increase the efficiency of the wickingprocess, and thus, the overall efficiency and effectiveness of a fluidconditioning system.

According to certain embodiments, the wicking material comprises one ormore of the following characteristics that assist in transferring waterand other condensation from the cold side to the hot side of the thermalmodule. The wicking material can have a low thermal conductivity so asto provide at least a partial thermal barrier between the cold side andthe hot side when no condensation is present. Further, the wickingmaterial may provide high capillary action. This capillary action may bein only one direction so as to ensure that the water and othercondensation are properly transferred to the hot side of the module. Inaddition, the wicking material can comprise anti-fungal, anti-bacterialand/or other characteristics that help prevent the growth of potentiallyharmful or undesirable microorganisms thereon or therein.

In some embodiments, the wicking materials are configured to withstandrelatively large variations in temperature (e.g., both short term andlong term changes), relative humidity and/or the like. For example, thematerial can be adapted to withstand a temperature range ofapproximately 40 to 85 degrees Celsius. The wicking material cangenerally have a high resistance to air flow, while allowing moisture towick therethrough. As a result, passage of cooled fluid from the coldside to the hot side of the thermal module can be reduced or minimized.Moreover, the wicking material can be configured so that it has littleor no dimensional distortion during use. In addition, according tocertain arrangements, the wicking material is configured to withstandthe forces, moments, pH variations and/or other elements to which it maybe subjected during its useful life. In some embodiments, the wickingseparator gasket and/or the finger wick members comprise polypropylene,nylon, other porous or non-porous materials and/or the like.

Condensation Sensors

As discussed herein with reference to wicking materials (FIGS. 2-5), onesolution to the above-identified condensate formation problems is todeal with the condensation directly. In other words, allow thecondensation to occur and then remove it (e.g., direct it from the coldside to the hot side using a wicking material). This can allow theclimate conditioning system to perform at or near a desired level ofcooling or heating.

In other embodiments, it may be desirable or necessary to detect thepresence of such condensates within or near a TED or other portion of athermal module. Thus, as discussed in greater detail herein, a robustyet cost effective sensor to detect the presence of condensation can beprovided. Accordingly, once the presence of water and/or other fluids isdetected by such sensors, the system can be configured to take one ormore steps to eliminate the condensation or to otherwise remedy theproblem. For example, according to one embodiment, once a sensor detectsa threshold level of condensate within or near a TED, the system isdesigned to reduce the voltage supplied to the TED until thecondensation has been completely or partially removed or reduced. Such areduction in voltage can reduce the extent to which fluids passingthrough the thermal module are cooled or heated, thereby reducing orstopping the formation of condensate. Such sensors can be utilized on orwithin any variety of climate conditioning systems and may be placed inany area where condensation is likely to pool or otherwise form.

In one embodiment, a sensor detects the presence of water and/or otherfluids by a change in electrical resistance. In other embodiments,sensors detect the presence of condensation by a change in electricalcapacitance. Additional details regarding condensate sensors configuredto be used in climate controlled seat assemblies are provided herein.

FIGS. 6A-6E illustrate various embodiments of sensors configured todetect the presence of water and other fluids by measuring a change inelectrical resistance. As shown in FIGS. 6A and 6B, a sensor 40 cancomprise a pair of electrical traces 41, 43 or other conductive members.According to some embodiments, the sensor 40 is designed to continuouslymonitor the resistance between the adjacent traces 41, 43. Any of thecondensate sensors disclosed herein can be configured to continuously orintermittently monitor the resistance, capacitance or any other propertyacross adjacent traces, as desired or required. Theoretically, thetraces form an open circuit; however, in reality, there may be ameasurable resistance across the traces 41, 43, such as, for example,about 10 mega-Ohms. The presence of a fluid on the sensor 40 can changethe measured resistance across the traces 41, 43. Since many fluids,such as, for example, water, are at least partially electricallyconductive, the presence of a fluid that electrically connects traces41, 43 can change the resistance to a measurable degree. Therefore, thecircuit formed by the adjacent traces 41, 43 can be “closed.”

According to some embodiments, a climate control system is configured sothat a change in resistance measured at the sensor 40 triggers a drop involtage to the TED 18 in order to decrease the cooling effect by theTED. With the conditioned fluid not as cool as before the drop involtage, condensation formation may decrease or stop. Either way, thevoltage can be adapted to remain at a lower level until the electricalresistance increases above a preset or threshold level or until anotheroperational criterion is satisfied (e.g., the passage of a particulartime period, a particular upper or lower ambient temperature is met,etc.).

The layout, size, spacing, general orientation and/or other detailsregarding the traces may vary, as required or desired. For example, suchdesign details can be varied based, at least in part, on the sensor'slocation within a TED, thermal module or other portion of a climateconditioning system, the space and geometry available at the targetedlocation, the methods used to manufacture the sensor or to create thetraces at the location, the target resistance across the traces (e.g.,without the presence of fluids, with the presence of fluids, etc.)and/or the like.

FIG. 6A illustrates one embodiment of a trace design. FIG. 6B shows thepotential zone of sensing Z for the design in FIG. 6A or the area mostlikely for the presence of fluid to bridge the traces 41, 43.Additionally, water and other fluids may not bridge traces 41, 43 iflocated at dead zones 45 (e.g., generally areas outside of the zone ofsensing Z). As shown in FIGS. 6A and 6B, the traces 41, 43 can includemain longitudinal portions and shorter arms or other members extendingtoward one another therefrom, in an alternating and repeating fashion.However, the traces 41, 43 can include a simpler or more intricatedesign, as desired or required. For example, as discussed herein withreference to FIG. 6E, a sensor can comprise generally straight traces41, 43 that parallel one another.

FIG. 6C illustrates a modified embodiment of a pair of electrical tracesconfigured for use in a condensation sensor. As shown, the potentialzone of sensing can be increased, because the distance between traces41′, 43′ is maintained at a generally equal spacing for substantiallythe entire length of the sensor. In any of the trace embodimentsdisclosed herein, or equivalents thereof, adjacent traces can be spacedsubstantially close to each other to quickly detect condensation. Thespacing between the traces may also be far enough apart so that minorcontaminations and other substances or occurrences do not lead to afalse detection of condensation.

FIG. 6D illustrates another embodiment of traces 41″, 43″ configured tobe used within a condensate sensor. The depicted traces 41″, 43″ can beconfigured to reduce the dead zones within a sensor. For example, thespacing between adjacent traces 41″, 43″ can be maintained constant orsubstantially constant. Thus, because of the circular nature of thetrace orientation, the presence of dead zones therein can beadvantageously reduced or eliminated. As discussed in greater detailherein, there may be other characteristics, besides the reduction ofdead zones, that may also be considered in the design of the sensor,such as, for example, cost and ease of manufacture, durability, abilityto resist corrosion, a target resistance across adjacent traces and/orthe like. Accordingly, any of the trace embodiments disclosed herein,including those illustrated in FIGS. 6A-6E, can be modified, as desiredor required to achieve a desired set of design criteria.

FIG. 6E illustrates yet another embodiment of electrical traces 41′″,43′″ configured to be used in a condensation sensor. As shown, thetraces 41′″, 43′″ can comprise substantially straight portions that aregenerally parallel to each other. Any other trace configuration can beused in a condensate sensor.

Another embodiment of a resistance-based sensor 90 configured to detectthe presence of water or other liquids on or near a TED or other portionof a thermal module is illustrated in FIG. 7. As shown, the sensor 90can include a high resistance exposed chip sensor or other surfacemounted device (SMD). For example, such a SMD can be similar to a bareresistor, capacitor or other chip device that is configured to besecured to a circuit board. The sensor 90 can include a main bodyportion 92 having a relatively high electrical resistivity. According tocertain arrangements, the main body portion 92 comprises solid or porousalumina ceramic or the like. The sensor 90 can include ends 94comprising tin or another material configured to be soldered to anadjacent conductive strip or trace. Thus, as shown, the sensor 90 can besized, shaped and otherwise configured to extend across adjacentconductive traces 41, 43 positioned on or near a TED or other targetedportion of a thermal module.

With continued reference to FIG. 7, the sensor 90 can be soldered orotherwise placed in electrical communication with electrical traces 41,43 or other conductive members across which a resistance can bemeasured. Thus, such a sensor 90 can advantageously permit the traces41, 43 or other conductive members to which the sensor attaches to beselectively coated or otherwise shielded with one or more protectivecoatings, layers or other members. This can help extend the life of thetraces 41, 43. In addition, such embodiments can simplify the manner inwhich one or more sensors 90 are provided within a TED or other portionof a thermal module.

According to some arrangements, when water or other condensation formson or near the sensor 90, such fluids can enter within or onto the mainbody portion 92 via wicking, absorption, through one or more openingsand/or the like. Consequently, the presence of water or other fluidswithin and/or on the main body portion 92 of the sensor 90 can lower theelectrical resistance across the two ends 94. Thus, as discussed hereinwith reference to other sensor embodiments, such a change in resistancecan confirm the presence of condensation within the thermal module. As aresult, one or more corresponding actions can be taken to adjust theoperation of the climate control system (e.g., reduce or cut-offelectrical current to the TED).

In any of the embodiments of sensors or other electrical devicesdisclosed herein, including but not limited to the sensors discussedwith reference to FIGS. 6A-6E and 7, the electrical traces or otherconductive members can be coated with one or more materials. Forexample, tin, silver, gold and/or any other conductive orsemi-conductive materials can be plated, soldered or otherwise disposedonto the traces, either partially or completely. Such coatings and othermaterials can help protect the underlying traces, which in someembodiments comprise copper and/or other materials generally susceptibleto corrosion, oxidation and other environmentally-induced damage. As aresult, such protective materials can help extend the life of thesensors and/or other components of a thermal module.

In certain embodiments, under normal circumstances, the resistancechange across adjacent traces measured by the sensor may changegradually over time. For example, with the accumulation of oxides, otherdeposits and/or other materials on or near the traces, the resistancebetween the traces can change, usually decrease, even without thepresence of condensate. In contrast, when condensate is present, theresistance across the traces decreases at a relatively faster rate(e.g., within seconds or minutes), depending, at least in part, on therate of condensation formation and accumulation.

Therefore, the thermal module and/or other portions of a climate controlassembly can be configured to respond to either an absolute decrease inelectrical resistance or a decrease in resistance that occurs over ashorter time period. In the first situation, a decrease in electricalresistance below a specified threshold level could trigger acorresponding drop in voltage supplied to the TED so as to decrease oreliminate the formation of additional condensate within the fluidmodule. However, this can be undesirable, as the decrease in resistancemay be caused by normal degradation (e.g., oxidation, accumulation ofother deposits and substances) rather than the actual presence ofcondensation.

On the other hand, under the “rapid change” operating scenario, acontrol system for the TED and other components of a thermal module canbe configured to modify the voltage supplied thereto only if thedecrease in electrical resistance measured across the traces occurswithin a specific time period. Thus, such embodiments could bebeneficial in more accurately detecting the presence of water or otherliquids on or near a TED. Accordingly, this can avoid a false positive,where the sensor incorrectly triggers a reduction in voltage to the TED.By having the sensor measure a rapid change in electrical resistanceover a shorter period of time, some of the long term problems associatedwith corrosion of the sensor, the accumulation of deposits on or nearthe sensor's traces and/or the like may be avoided.

One embodiment of a graph G illustrating decreases in electricalresistance across a condensation sensor over time is provided in FIG. 8.As shown, the electrical resistance across a sensor's traces cangradually decrease over time due to corrosion, the accumulation of dirt,deposits or other substances on or near the sensor's traces and/or anyother factor or reason. As discussed herein, this is typical for manyembodiments of condensation sensors used in TEDs, thermal modules andsimilar environments. By way of example, during a first time period t₁,the resistance can decrease by a first resistance value R₁ (e.g., a dropin overall resistance, a drop in percentage of resistance, etc.). Such afirst time period t₁ may comprise days, months or years, depending onthe particular environmental and operating conditions to which thesensor is subjected.

With further reference to FIG. 8, electrical resistance can drop by asecond resistance value R₂ due primarily to the accumulation of water orother condensation across the a sensor. The time period during whichsuch a resistance drop R₂ occurs can be substantially short (e.g.,seconds, minutes, etc.), especially when compared to R₁. Thus, assumingthe drops in total resistance (or percentage of resistance) representedby R₁ and R₂ are generally equal, a sensor that does not take time intoaccount would not be able to distinguish between the gradual drop inresistance over time period t₁ and the rapid drop over t₂. Consequently,the sensor may not be able to adequately detect the presence ofcondensation.

In order to remedy such a discrepancy, in some embodiments, a climatecontrol system is configured to compare a particular drop in resistancemeasured across a sensor in the context of the time period that such adrop occurred. Thus, a system may be configured to modify the voltagesupplied to a TED only when the condensate sensor detects a specificdrop in resistance value or percentage over a minimum time period. Forexample, according to certain configurations, a system will adjust thetemperature of a TED if the resistance drops by at least 5%, 10%, 15%,20%, more than 20% or some other value over a 1-minute, 2-minute,5-minute, 10-minute, 15-minute, 30-minute or other time period. In otherarrangements, the minimum percentage of resistance drop and/or the timeperiod over which such a resistance drop must occur can be varied, asdesired or required.

In some embodiments, electrical traces can be etched onto a surface. Asdiscussed in greater detail herein, such a surface can be on or form apart of a TED 18, a fluid distribution system 12 or other device orcomponent of a climate-controlled system for a seating assembly (FIGS. 1and 2) or any other device.

The sensor will now be discussed in relation to the TED 218 illustratedin FIGS. 9A and 9B. As shown, the TED 218 can include a plurality ofdissimilar conductive elements or pellets 222, 224. In somearrangements, pairs of dissimilar conductive elements 222, 224 arecoupled together by a series of electrical joining elements or tabs 228,which are, in turn, disposed between a pair of opposing substrates 232.The substrates 232 can comprise polyimide, ceramic, epoxy or anothermaterial that has desirable electrical insulation and thermal conductiveproperties. In the depicted embodiment, each substrate 232 is thermallycoupled to a heat transfer member 238 (e.g., fins) through one or morecopper pads 234 or other support members. In some embodiments, a seal260 is optionally provided between the opposing substrates 232 to helpprotect the elements 222, 224 that are situated therebetween.

One or more condensation sensors, in accordance with the variousembodiments disclosed herein, can be used with the TED 218 to detect thepresence of water or other fluids. In some embodiments, the sensor islocated on, along or near the substrate, generally on the side oppositethe pellets at the downstream side of the TED. Since in somearrangements, the cold-downstream side of the TED is the coldestlocation or one of the coldest locations in the thermal module,condensation is likely to form at or near this location. However, inother embodiments, one or more condensation sensors are positioned on,along or near a different portion of the TED 218 (e.g., fins, copperpads, etc.), the thermal module and/or other portions of the climatecontrol seat assembly, as desired or required. Thus, the embodimentsdisclosed herein, including the advantages, features and other detailsprovided therewith, can be applied to any condensation sensor includedwithin the climate control seat assembly, regardless of its location,type and/or other characteristics.

FIG. 10A illustrates a different embodiment of a fluid module 214′. Asshown, the TED 218′ can include a substrate 320 which is generallylonger than an adjacent thermal conductive element 234′ and which mayform a ledge or shelf. In some embodiments, a sensor 240 is formed onthe ledge 270 of substrate 320. A portion of the air or other fluid thatenters through the inlet 250′ of the fluid module 214′ is diverted tothe main side 252′ and passes by the heat transfer member 238′ (e.g.,fins). In some arrangements, fluid passing by the heat transfer member238′ of the main side is selectively cooled. Consequently, condensationmay form on the heat transfer member 238′ and/or elsewhere on the TED218′ or the fluid module 214′. Some condensation can contact the sensor240, which may be configured in accordance with one of the embodimentsdisclosed herein or a variation thereof. Thus, the sensor 240 can beconfigured to detect the condensation and, either directly orindirectly, trigger a decrease in voltage supplied to the TED 18′. Forexample, in some embodiments, the sensor 240 is operatively connected toa controller that is adapted to receive data from the sensor and adjustthe voltage supplied to the TED accordingly. FIG. 10B shows anotherembodiment of a TED 218″ that comprises a sensor 400 along a ledge 270″or other extension of the substrate 320′. The quantity, type, size,shape, location and/or other details regarding the condensation sensorsused in a TED and/or other portions of a thermal module or climatecontrol system can vary, as desired or required.

In certain embodiments, as illustrated in FIG. 10C, the TED 218″″includes fins 238″ (or other heat transfer members) along its waste side255″″ but not along its main side 252″″. Such an arrangement can be usedto heat or cool a particular item placed in thermal communication withthe main side 252″″ of the TED 218″″. In some embodiments, suchconfigurations are used to selectively heat and/or cool beveragecontainers or the like. By way of example, an item 101 to be chilled(e.g., a beverage container, a food item, etc.) may be placed directlyon the main side 252″″ of the TED. When the TED 18″″ is activated (e.g.,electrically energized), the main side 252″″ can be configured to cool.Consequently, the item 101 can be conductively and/or convectivelycooled. In some arrangements, one or more condensate sensors 240″″ arepositioned on a ledge 270″″ of the substrate, another portion of thesubstrate 320″″ and/or any other location of the TED 218″″. For example,a condensate sensor is provided on or along the same surface as the item101 to be chilled.

According to some embodiments, a sensor is configured to detect thepresence of water and/or other condensation by measuring electricalcapacitance. Such sensors may function in a similar manner as theresistance-based sensors in that a change in capacitance can becorrelated to the presence of condensation on or near a sensor.Accordingly, the climate control system can be configured to decreasethe voltage supplied to the TED in order to partially or completelyeliminate such condensate from the system.

As discussed, in any of the embodiments disclosed herein, a climatecontrol system can be configured to restore the electrical currentsupplied to one or more TEDs to its original or other value once thesensor no longer detects the presence of condensate.

In some arrangements, a capacitance based sensor can provide certainadvantages over resistance based sensors. For example, as discussed ingreater detail herein, resistance based sensors can be susceptible todamage (e.g., by corrosion, contamination, etc.). Likewise, however,there may be certain situations where a resistance based sensor may befavored over a capacitance based sensor. In discussing any shortcomingswith regards to various alternatives herein, such as, for example,condensation sensors, applicant in no way disavows the use of any of thedevices, systems, methods, design features and/or other characteristicsor aspects of such embodiments or equivalents thereof, as each situationmay require a balancing of features and criteria, which balancing may bedifferent for other situations.

FIG. 11A illustrates one embodiment of a capacitance based sensor 280.As shown, the sensor 280 can comprise a first plate 281, a second plate283 and a material 285 or central portion generally located between thefirst plate 281 and the second plate 283. The first plate 281 and thesecond plate 283 can include one or more conductive materials. Thematerial 285 or central portion of the sensor 280 can comprise one ormore materials that are configured to absorb fluids (e.g., water, otherliquids, condensation and/or the like). According to some embodiments,as the moisture level within the material 285 changes, the capacitancemeasured across the first plate 281 and the second plate 283 alsochanges. A change in capacitance above a certain set point or threshold,as measured by a sensor 280, can be configured to cause a reduction inthe voltage supplied to a TED. In some arrangements, such a TED can beadapted to operate at the reduced voltage until the capacitance measuredacross the first plate 281 and the second plate 283 returns to apredetermined or satisfactory level. For example, the voltage to the TEDmay be raised once the capacitance increases above the same thresholdthat caused a reduction in voltage. Thus, when the capacitance increasesabove a given setpoint, a controller operatively connected to the sensorand the TED directs the voltage supplied to the TED to be returned tothe original level. In other embodiments, the climate control system isconfigured to have two or more different capacitance levels orthresholds above or below which the voltage supplied to the TED ismodified (e.g., increased, decreased, etc.).

According to certain configurations, a change in capacitance measured atthe sensor 280 results in a drop in voltage to the TED, in order todecrease the cooling effect on the fluid being thermally conditioned.Thus, since the conditioned fluid is not as cold as it was before thevoltage reduction, condensation formation can advantageously stop ordecrease. As discussed, in such circumstances, the voltage can remain ata lower level until the capacitance increases above a desired threshold.Once the desired threshold capacitance is achieved, the supply ofelectrical current to the TED can be restored, either to a previouslevel or another level, in accordance with a desired control scheme.

In some arrangements, capacitance based sensors are advantageously usedin TEDs that comprise flexible substrates. However, resistance based orother types of condensation sensors can also be used for such TEDs. Insome embodiments where the TEDs include ceramic substrates, resistancebased condensation sensors can be used.

According to some embodiments, the material 285 or central portion,which is positioned generally between the conductive plates 281, 283 ofa capacitance based sensor 280, can also serve as a substrate layer fora TED. For example, flexible substrates, such as polyimide, can beadapted to absorb fluids. Thus, as such substrates absorb water or otherfluids formed on or within a TED, the sensor 280 can detect acorresponding change in capacitance measured across its plates 281, 283.As polyimide is generally highly hydroscopic, it is well-suited for suchan application. In other embodiments, one or more other materials can beused to serve the dual role of a TED substrate and a material layer fora capacitance based condensate sensor. Further, even materials that haveaverage or poor hydroscopic characteristics, such as, for example,ceramics, can be modified (e.g., combined with other materials, providedwith a porous structure, etc.) in order to use them in suchapplications.

With reference to FIG. 11B, a capacitance based sensor can comprise,among other things, a thermal conductive element 134, electrical joiningelements or tabs 128 and a substrate 132. In some embodiments, thethermal conductive element 134 and the electrical joining elements 128can be configured to serve as the first 281′ and second 283′ conductiveplates of a sensor, respectively. The substrate 132 can effectively bethe material or central portion of the capacitance based sensor that isgenerally positioned between upper and lower conductive plates. Asdiscussed, the substrate 132 can comprise one or more materials thatabsorb water and other fluids. Accordingly, as the substrate absorbscondensation, the capacitance measured across the first 281′ and second283′ conductive plates may change. Such a change in capacitance cansignal that an undesirable amount of condensate exists at or near theTED. Thus, the climate control system can be advantageously configuredto reduce the amount of voltage being supplied to the TED. In someembodiments, the first 281′ and second 283′ conductive plates comprisecopper and/or another highly conductive material.

In certain embodiments, the substrate layer used in TEDs can berelatively thin. For example, the thickness of a polyimide substrate maybe less than 0.001 inch (0.025 mm). Therefore, the surface area exposedfor moisture absorption may also be relatively small. For example, theexposed surface area may include only the length of an exposed edge. Insome embodiments, the exposed surface area is increased by variousmethods. For example, the first conductive plate 281′ can include anorifice to allow for more enhanced moisture absorption. In otherembodiments, the first conductive plate 281′ comprises a plurality oforifices. The orifices can be positioned in or along one localized area.Alternatively, such orifices can be spread out generally along the firstconductive plate 281′. In other arrangements, the orifices areconcentrated at locations where the likelihood of condensation formationis relatively high, such as, for example, on the main side, generallydownstream of the airflow of the TED. In other configurations, theorifices are located on a ledge or other protruding member or portionthat extends beyond the main side heat transfer member 138 of the TED.

FIG. 12 schematically illustrates a condensation sensor 40, inaccordance with any of the embodiments disclosed herein (e.g.,resistance based sensors, capacitance based sensors, etc.), which hasbeen incorporated into an electrical circuit. In some embodiments, anoff-the-shelf or otherwise commercially available sensor can be usedwithin or near a thermal module and/or other location of a climatecontrol system, either in lieu of or in addition to any of the specificsensor embodiments disclosed herein. As shown, a voltage can be measuredacross the sensor 40 with a voltage (e.g., 5V) and a resistance (e.g., 1mega-Ohm) applied upstream of the sensor 40.

While the condensate sensors disclosed herein are generally described inthe context of TEDs and climate control systems for seating assemblies,it will be appreciated that such embodiments, and variations thereof,are applicable to other applications as well. For example, such sensorscan be used in conjunction with any heating and/or cooling system inwhich condensation is likely to form or in which water or other liquidsare likely to accumulate. Further, such sensors can be used to detectcondensation on printed circuit boards for electric devices, otherelectronic components and/or any other electrical or mechanical devicewhere removal of fluids from portions thereof is important. In otherembodiments, such sensors can be stand alone electronic sensors thatgenerate a signal (e.g., 5V) when condensation forms.

Control Schemes Using Relative Humidit and/or Temperature Detection

A climate control seating assembly, such as, for example, a vehicleseat, a bed, a wheelchair, another medical bed or chair and/or the like,can be advantageously configured to automatically operate within adesired comfort zone. One embodiment of such a comfort zone (generallyrepresented by cross-hatched area 510) is schematically illustrated inthe graph 500 of FIG. 13. As shown, a desired comfort zone 510 can bebased, at least in part, on the temperature and relative humidity of aparticular environment (e.g., ambient air, thermally conditioned air orother fluid being delivered through a climate controlled seat assembly,etc.). Thus, if the relative humidity is too low or too high for aparticular temperature, or vice versa, the comfort level to an occupantsituated within such an environment can be diminished or generallyoutside a target area.

For example, with reference to a condition generally represented aspoint 520C on the graph 500 of FIG. 13, the relative humidity is toohigh for the specific temperature. Alternatively, it can be said thatthe temperature of point 520C is too high for the specific relativehumidity. Regardless, in some embodiments, in order to improve thecomfort level of an occupant who is present in that environment, aclimate control system can be configured to change the surroundingconditions in an effort to achieve the target comfort zone 510 (e.g., ina direction generally represented by arrow 520C). Likewise, a climatecontrol system for a seating assembly situated in the environmentalcondition represented by point 520D can be configured to operate so asto change the surrounding conditions in an effort to achieve the targetcomfort zone 510 (e.g., in a direction generally represented by arrow520D). In FIG. 13, environmental conditions generally represented bypoints 520A and 520B are already within a target comfort zone 510. Thus,in some embodiments, a climate control system can be configured tomaintain such surrounding environmental conditions, at least while anoccupant is positioned on the corresponding seating assembly (e.g.,vehicle seat, bed, wheelchair, another medical bed or chair, etc.).

In some embodiments, a climate control system for a seating assembly isconfigured to include additional comfort zones or target operatingconditions. For example, as illustrated schematically in FIG. 13, asecond comfort zone 514 can be included as a smaller area within a maincomfort zone 510. The second comfort zone 514 can represent acombination of environmental conditions (e.g., temperature, relativehumidity, etc.) that are even more preferable that other portions of themain comfort zone 510. Thus, in FIG. 13, although within the maincomfort zone 510, the environmental condition represented by point 520Bfalls outside the second, more preferable, comfort zone 514. Thus, aclimate control system for a seating assembly situated in theenvironmental condition represented by point 520B can be configured tooperate so as to change the surrounding conditions toward the secondcomfort zone 514 (e.g., in a direction generally represented by arrow520B).

In other embodiments, a climate control system can include one, two ormore target comfort zones, as desired or required. For example, aclimate control system can include separate target zones for summer andwinter operation. In such arrangements, therefore, the climate controlsystem can be configured to detect the time of year and/or the desiredcomfort zone under which a climate controlled seat assembly is to beoperated.

The incorporation of such automated control schemes within a climatecontrol system can generally offer a more sophisticated method ofoperating a climate control seat assembly (e.g., bed). Further, asdiscussed herein, such schemes can also help to simplify the operationof a climate controlled seat assembly and/or to lower costs (e.g.,manufacturing costs, operating costs, etc.). This can be particularlyimportant where it is required or highly desirable to maintain athreshold comfort level, such as, for example, for patients situated onwheelchairs, medical beds and/or the like. Further, such control schemescan be especially useful for seating assemblies configured to receiveoccupants that have limited mobility and/or for seating assemblies whereoccupants are typically seated for extended time periods (e.g., beds,airplane seats, other vehicle seats, movie theaters, hospital beds,convalescent beds, wheelchairs, other medical beds or chairs, etc.).

According to some embodiments, data or other information obtained by oneor more sensors is used to selectively control a climate control systemin order to achieve an environmental condition which is located within adesired comfort zone 510, 514 (FIG. 13). For instance, a climate controlsystem can include one or more temperature sensors and/or relativehumidity sensors. As discussed in greater detail herein, such sensorscan be situated along various portions of a seating assembly (e.g., TED,thermal module, fluid distribution system, inlet or outlet of a fluidtransfer device, fluid inlet, surface of an assembly against which anseated occupant is positioned, etc.) and/or any other location withinthe same ambient environment as the seating assembly (e.g., an interiorlocation of a automobile, a bedroom, a hospital room, etc.). In otherembodiments, one or more additional types of sensors are also provided,such as, for example, an occupant detection sensor (e.g. configured toautomatically detect when an occupant is seated on a vehicle seat, a bedand/or any other seating assembly).

Regardless of the quantity, type, location and/or other detailsregarding the various sensors included within a particular assembly, thevarious components of the climate control system can be configured tooperate (in one embodiment, preferably automatically) in accordance witha desired control algorithm. According to some embodiments, the controlalgorithm includes a level of complexity so that it automatically variesthe amount of heating and/or cooling provided at the seating assemblybased, at least in part, on the existing environmental conditions (e.g.,temperature, relative humidity, etc.) and the target comfort zone.

Accordingly, in some embodiments, a control system for a climate controlseating assembly is configured to receive as inputs into its controlalgorithm data and other information regarding the temperature andrelative humidity from one or more locations. For example, asillustrated in FIG. 14A, a climate controlled vehicle seat 600 caninclude fluid distribution systems 612, 622 along its seat back portion602 and/or seat bottom portion 604. Each fluid distribution system 612,622 can be in fluid communication with a fluid transfer device 616, 626(e.g., fan, blower, etc.) and a thermoelectric device 618, 618 (e.g., aPeltier circuit, other device configured to selectively temperaturecondition air or other fluids passing therethrough, etc.). In theillustrated arrangement, a temperature sensor 630, 632 is located withinor near each thermoelectric device 618, 628. Such sensors 630, 632 canbe configured to detect the temperature of the TED, the temperature of afin or other heat transfer member, the temperature of any other portionor components of the TED, the operating temperature of the TED, thetemperature of the fluid within, entering or exiting the fins or otherportion of the TED, the temperature upstream or downstream of the TED,the temperature upstream or downstream of the fluid transfer device, thetemperature within the fluid distribution system 612, 622 and/or thetemperature along any other portion of the thermal module or the seatassembly.

With continued reference to FIG. 14A, one or more sensors 654, 656 canbe provided on a controller 650 and/or any other location surroundingthe seat assembly 600, either in lieu of or in addition to thetemperature sensors 630, 632 included on or near the TEDs. For instance,the depicted controller 650 can include a sensor 654 configured todetect the ambient temperature. Further, the controller 650 may alsoinclude a sensor 656 configured to detect the relative humidity of thesurrounding environment (e.g., the interior or exterior of anautomobile). Although not included in the depicted arrangement, one ormore additional relative humidity sensors can be provided on or near theTEDs, within the fluid distribution systems of the seat assembly 600,any location where a temperature sensor is located (e.g., upstream ordownstream of a fluid transfer device) and/or the like. Such relativehumidity sensors can be configured to provide additional operationaldata that may further enhance the ability of a climate control system toautomatically operate within a desired comfort zone 510, 514 (FIG. 13).

As illustrated in FIG. 14A, the controller 650 can be operativelyconnected to the various sensors 630, 632, 654, 656 located within or inthe vicinity of a climate control seat assembly 600. Informationreceived from the various sensors can be used to automatically regulateone or more devices or aspects of the climate control system, such as,for example, TEDs 618, 628 (e.g., the amount of voltage suppliedthereto), the fluid transfer devices (e.g., the rate of which air istransferred through the fluid distribution systems 612, 622) and/or thelike. In other embodiments, the controller 650 is also operativelyconnected to one or more external climate control systems (e.g., theautomobile's or building's HVAC system). This can further enhance theability of the climate control system to achieve a desired operatingcondition.

In other embodiments, as illustrated in the bed assembly 700 of FIG.14B, both a temperature sensor 730, 732 and a relative humidity sensor740, 742 are provided within or near each TED 718, 728 or fluid modulein which such TED is positioned (e.g., the inlet of the fluid transferdevice 716, 726). In other arrangements, additional temperature and/orrelative humidity sensors 754, 756 are included within other portions ofthe bed assembly 700 (e.g., within the lower portion 714 and/or upperportion 712, within a fluid distribution member 712, 713, etc), on acontroller 750, on a wall of the room in which the bed assembly 700 ispositioned and/or the like.

Regardless of the quantity, location, type and/or other detailsregarding the various sensors used in conjunction with a climate controlsystem, such sensors can be advantageously configured to provide dataand other information regarding the temperature and relative humidity ofambient air, the operational temperature of a particular climatecontrolled seating assembly (e.g., vehicle seat, bed, a medical bed,wheelchair, another medical chair, etc.) and/or the like to permit theseating assembly to be operated (e.g., automatically, if so desired)within a target comfort zone.

For example, as discussed herein with reference to FIG. 14A, theinformation transmitted from the various sensors to a controller can beused to automatically turn on or off and/or modulate various componentsof a climate controlled bed 700 or other seating assembly. In somearrangements, the fluid transfer devices and/or the TEDs are turned onor off, in accordance with a desired control scheme. As discussed, suchbeds and other seating assemblies can additionally include an occupantdetection sensor that allows a control system to be notified when a useris seated or otherwise positioned thereon. Thus, a bed assembly 700 canbe configured to automatically turn on or off and/or provide variouslevels of heated and/or cooled air when an occupant positions himself orherself thereon. This can advantageously eliminate the need for one ormore manual controls (e.g., switches, controllers, etc.) that mayotherwise be supplied with a climate controlled bed 700 or other seatingassembly. Thus, such automated operational schemes can advantageouslyreduce both the cost and the complexity of providing and operating aclimate controlled bed or other assembly.

In any of the embodiments disclosed herein, or equivalents thereof, therelative humidity sensors can be capacitance-based, resistance-based,thermal conductivity based and/or the like.

In simpler embodiments, a control algorithm is configured to receiveonly temperature data from one or more sensors. Alternatively, onlyrelative humidity sensors can be used to provide information to aclimate control system about the existing environmental conditionswithin or near a target seating assembly. In still other embodiments,additional information regarding the surrounding environment is providedto the control system, such as, for example, time of day, whether theambient temperature is decreasing or increasing and/or the like.Accordingly, a target comfort zone 510 (e.g., FIG. 13) can be based onone, two, three or more variables, as desired or required.

Further, any of these control schemes can be used together with acondensation sensor and/or a wicking flow separator as discussed andillustrated in greater detail herein. For example, a control schemeoperating within a target comfort zone can be overridden if acondensation sensor detects the presence of an undesirable level offluid within the TED and/or other locations of the thermal module.Alternatively, the control scheme can be configured to continueoperating toward a target comfort zone if a wicking material is providedwithin the thermal module to properly avoid condensation formation.

The systems, apparatuses, devices and/or other articles disclosed hereinmay be formed through any suitable means. The various methods andtechniques described above provide a number of ways to carry out theinvention. Of course, it is to be understood that not necessarily allobjectives or advantages described may be achieved in accordance withany particular embodiment described herein. Thus, for example, thoseskilled in the art will recognize that the methods may be performed in amanner that achieves or optimizes one advantage or group of advantagesas taught herein without necessarily achieving other objectives oradvantages as may be taught or suggested herein.

Furthermore, the skilled artisan will recognize the interchangeabilityof various features from different embodiments disclosed herein.Similarly, the various features and steps discussed above, as well asother known equivalents for each such feature or step, can be mixed andmatched by one of ordinary skill in this art to perform methods inaccordance with principles described herein. Additionally, the methodswhich are described and illustrated herein are not limited to the exactsequence of acts described, nor are they necessarily limited to thepractice of all of the acts set forth. Other sequences of events oracts, or less than all of the events, or simultaneous occurrence of theevents, may be utilized in practicing the embodiments of the invention.

Although the invention has been disclosed in the context of certainembodiments and examples, it will be understood by those skilled in theart that the invention extends beyond the specifically disclosedembodiments to other alternative embodiments and/or uses and obviousmodifications and equivalents thereof. Accordingly, it is not intendedthat the invention be limited, except as by the appended claims.

1-20. (canceled)
 21. A fluid module for selectively heating and/orcooling air, the fluid module comprising: a thermoelectric device havinga cold side and a hot side; a cold side comprising a cold side heatexchanger coupled to the cold side of the thermoelectric device and acold side outlet in fluid communication with the cold side heatexchanger; a hot side comprising a hot side heat exchanger coupled tothe hot side of the thermoelectric device and a hot side outlet in fluidcommunication with the hot side heat exchanger; and a separator gasketseparating at least in part the cold side outlet from the hot sideoutlet, the separator gasket configured to draw condensate away from atleast a portion of the cold side to the hot side.
 22. The fluid moduleof claim 21, wherein the separator gasket comprises one or more wickingmaterials that separates at least in part the cold side outlet from thehot side outlet.
 23. The fluid module of claim 22, wherein the one ormore wicking materials comprise polypropylene or nylon.
 24. The fluidmodule of claim 21, wherein the separator gasket includes at least onefinger that extends into the cold side heat exchanger.
 25. The fluidmodule of claim 24, wherein the at least one finger extends next to oneor more fins that form at least in part the cold side heat exchanger.26. The fluid module of claim 21, wherein the separator gasket includesat least one finger that extends into the cold side heat exchanger. 27.The fluid module of claim 26, wherein the at least one finger extendsnext to at least one or more fins that form at least part of the coldside heat exchanger.
 28. The fluid module of claim 21, comprising afluid transfer device positioned upstream of the thermoelectric device,the fluid transfer device in fluid communication with the cold side heatexchanger and the hot side heat exchanger.
 29. The fluid module of claim21, comprising a fluid transfer device positioned downstream of thethermoelectric device, the fluid transfer device in fluid communicationwith the cold side outlet and the hot side outlet.
 30. The fluid moduleof claim 21, wherein the separator gasket comprises a porous structure.31. A method of selectively heating and/or cooling air, the methodcomprising: transferring air to a cold side of a fluid module, the coldside of the fluid module comprising a cold side heat exchanger coupledto a cold side of a thermoelectric device and a cold side outlet influid communication with the cold side heat exchanger; transferring airto a hot side of the fluid module, the hot side of the fluid modulecomprising a hot side heat exchanger coupled to a hot side of thethermoelectric device and a hot side outlet in fluid communication withthe hot side heat exchanger; and wicking condensate away from at least aportion of the cold side of the fluid module via a separator gasket. 32.The method of selectively heating and/or cooling air of claim 31,further comprising wicking the condensate to the hot side of the fluidmodule via the separator gasket.
 33. The method of selectively heatingand/or cooling air of claim 31, further comprising evaporating thecondensate on the hot side of the fluid module.
 34. The method ofselectively heating and/or cooling air of claim 31, wherein wickingcondensate away from at least a portion of the cold side of the fluidmodule comprises wicking condensate through the separator gasket,wherein the separator gasket separates the cold side outlet from the hotside outlet.
 35. The method of selectively heating and/or cooling air ofclaim 34, wherein wicking condensate away from at least a portion of thecold side of the fluid module comprises wicking condensate through atleast one finger wick that extends into the cold side heat exchanger.36. The method of selectively heating and/or cooling air of claim 35,wherein wicking condensate away from at least a portion of the cold sideof the fluid module wicking condensate through the at least one fingerwick comprises wicking condensate away between one or more fins thatform at least part of the cold side heat exchanger via the at least onefinger wick extending next to the one or more fins.
 37. The method ofselectively heating and/or cooling air of claim 31, wherein wickingcondensate away from at least a portion of the cold side of the fluidmodule comprises wicking condensate through at least finger wick thatextends into the cold side heat exchanger.
 38. The method of selectivelyheating and/or cooling air of claim 31, wherein wicking condensate awayfrom at least a portion of the cold side of the fluid module compriseswicking condensate along at least one finger wick that extends next toone or more fins that form at least part of the cold side heatexchanger.
 39. The method of selectively heating and/or cooling air ofclaim 31, further comprising transferring air to the cold side heatexchanger and to the hot side heat exchanger through a fluid transferdevice positioned upstream of the thermoelectric device.
 40. The methodof selectively heating and/or cooling air of claim 31, furthercomprising transferring air to the cold side heat exchanger and to thehot side heat exchanger via a fluid transfer device positioneddownstream of the thermoelectric device.
 41. A fluid module forselectively heating and/or cooling air, the fluid module comprising: athermoelectric device having a cold side and a hot side; a cold sidecomprising a cold side heat exchanger coupled to the cold side of thethermoelectric device and a cold side outlet in fluid communication withthe cold side heat exchanger; a hot side comprising a hot side heatexchanger coupled to the hot side of the thermoelectric device and a hotside outlet in fluid communication with the hot side heat exchanger; anda separator gasket configured to draw condensate away from at least aportion of the cold side to the hot side.